Klinger News

www.klinger.chFebruary 2008

Getting emotional about KLINGER products and services KLINGER GmbH, Germany

The KLINGER GmbH portfolio comes under the heading of technical products and associated advice. To say it involves ‘emotionally charged’ products would be something most readers would certainly dispute. But if we look at the results we achieve through the proper use of our

Our contribution to a cleaner environ- ment: gasket mate-rials, perfectly deve-loped for their appli- cations, make sure that emissions and toxins cannot be released into the environment.

products, things start to look different. Our gasket materials and technical solutions do not only form a leak-tight joint. They also help protect the environment. They make sure that technology will be safer, and that new, energy-saving products can be created. Seen from this point of view, our products now attain a clear ‘emotional component’.

KLINGER GmbH will be taking account of this fact in its communications concept. «Our contribution to a cleaner environment» - that is the title of a series of images and graphics that form part of KLINGER’s advertising activities that make their public debut in the 2008 calendar. Life is full of emotions - so why not KLINGER technology as well? ■

Connectwith

Quality2008

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National and international standards provide criteria for classify-ing products and procedures in almost every technical field. As an inspection of KLINGERSIL® datasheets clearly shows, these standards also apply to sheeting materials. Reference to the relevant standards in our technical documentation will help classify materials and identify the specific characteristics of a product and thus assist users in making their choice. One of the most commonly used standards in the sealing sector is BS 7531. BS 7531:1992 provided criteria such as approvals, thickness tolerances, etc. for classifying rubber-bonded fibre jointing. More importantly, it laid down test methods and specifications that separated materials into Grade X and Grade Y, BS 7531:2006 introduced two additional grades - Grade AX and Grade AY, where the letter A indicates a material’s suitability for use in aerospace applications. The standard has thus been renamed: «Rubber Bonded Fibre Jointing for Industrial and Aerospace Purposes - Specifica-tion». Obviously, the standard places higher demands on aerospace grades than industrial grades. With a broad spec-trum of KLINGERSIL® materials already classified as industrial Grade X or grade Y, Rich. KLINGER Dichtungstechnik GmbH & CoKG has been checking the compliance of its materials with the additional higher aerospace requirements.

KLINGERSIL® materials ready for take-off Rich. KLINGER Dichtungstechnik GmbH & CoKG, Austria

It goes without saying that not all gaskets are the same. But how can one sheeting material be distinguished from another? The answer is simple: widely acknowledged sealing-related standards provide testing methods and specifications for clas-sifying jointing materials. One such standard is BS 7531, which in its latest revision introduces two new grades intended for use in aerospace applications.

Taking a closer look at BS 7531:2006, it is evident that the additional demands on Grade X, for example, to become Grade AX are related not only to material properties but also to production and testing. To produce an aerospace grade, it is essential that every single mix of raw materials is made with fully trace-able ingredients. Another non-material, property-related requirement is the frequency of testing. When producing aerospace grades, it is no longer sufficient to carry out one lab test for each run of production (which could amount to only one test every 5 tons). Instead, testing is required on each batch. But because a high level of quality awareness and sufficient lab capacity have been standard practice at Rich. KLINGER Dichtungstechnik GmbH & CoKG for many years, the above- mentioned requirements present no problems.

When it comes to material properties, the most important addi-tional requirement when upgrading from industrial to aerospace is compliance with a specified fluid resistance and flex-ibility. Materials have to pass additional immersion tests in Liquid 101 (synthetic ester-based lubrication oil), Oil No. 1 (paraffin oil) and Liquid B (gasoline), and must not exceed a determined change in properties. For this reason, only NBR bonded materials are intended for classification as grade AX or AY. Further-more, the flexibility of the materials has to be evaluated by a bending test to ensure slight embrittlement only. During recent months, the Rich. KLINGER Dichtungstechnik GmbH & CoKG

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KLINGERSIL® materials ready for take-off

laboratory has not only conducted the aforementioned tests, but all other tests required for classification according to the revised BS 7531:2006. The following KLINGER materi-als have now been released for aerospace purposes:

KLINGERSIL® C4400: Grade AYKLINGERSIL® C4430: Grade AXKLINGERSIL® C4500: Grade AXKLINGER® top-graph 2000: Grade AX KLINGER® top-sil-ML1: Grade AX

KLINGER WARBA signs up with Al Dorra Petroleum ServicesKLINGER Limited, United Kingdom

To extend its services to the local region, Kuwait-based gas-ket manufacturer KLINGER WARBA has joined forces with Al Dorra Petroleum Services, established in 2006 with a capital of KWD 40 million and one of the first companies in Kuwait to invest in specialised oil-sector companies.

Under license from KLINGER UK, KLINGER WARBA manufactures all types of gaskets for use in the oil and power sectors. The company has a number of exclusive, long-term supply agreements that include a 5-year contract with Quate Petrochemical Co. and a 4- year deal with KOC Kuwait Oil Com-pany. It has also signed to supply Pic Petrochemical Industries over a 2-year

period and the KNPC Kuwait National petroleum for a period of 5 years. According to Abdul Razzak Al Awadi, Director/President of WARBA National Group of Companies WNG: “The Al Dorra Group will invest in modernising the KLINGER WARBA factory and extend production facilities into cam profile and ring joint manufacturing. This investment will be completed by mid 2008.” ■

Abdul Razzak Al Awadi, Director/President WARBA National Group of Companies WNG and Alan Bates, Managing Director KLINGER UK signing a new agreement.

So fasten your seatbelts, put your seat back in the upright position, and enjoy your flight with KLINGERSIL® products! ■

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New Austrian bioethanol plant relies on the quality of KLINGER valves

A major success for KLINGER Gebetsroither: in cooperation with Pörner Ingenieursgesell-schaft, the new bioethanol plant at Agrana Bioethanol GmbH in Pischelsdorf (Lower Austria) has been equipped with KLINGER valves. A potentially record-breaking EUR 125 million investment makes this one of the largest ethanol generating facilities in Austria. The bioethanol generation process promoted by US technology supplier KATZEN International Inc. uses a mixture of wheat and corn as the main raw materials. A further component is juice concentrate from Agrana’s own sugar production. Like conventional alco-hol, bioethanol is acquired through the fermentation of sugar with the aid of micro-organisms, and then cleaned in a thermal separation procedure. Maximum annual production of agricultural fuel amounts to 190,000 tonnes. In addition, there’s also up to 170,000 tonnes per year of DDGS (Distillers Dried Grain with Solubles), a valuable high-protein animal feed supplement. A total of 2000 KLINGER Ballostar ball valves have been installed in the plant, the majority (1700) being two-piece split body KLINGER Ballostar KHE ball valves in cast and stainless steel. This represents an important success for the latest product in our Ballostar range and enables KFC to enter the market in a new, process-related application field. The operating media successfullly handled by KLINGER valves is not restricted to bioethanol alone. The following list shows the range of ball valve applications at a glance:

KLINGER Gebetsroither GmbH and KLINGER Fluid Control GmbH, Austria

KHE-FL in cast steel:Condensate, nitrogen, ethanol, and cooling, process and waste water.

KHE-FL in stainless steel: Instrumentation air, CIP solution, ethanol, mash and condensate.

KHA-G in cast steel:Condensate air and drinking water.

KHA-G in stainless steel:Instrumentation air, CIP solution, ethanol, mash, condensate, sulphuric acid, sodium hydroxide, and enzymes.

Thanks to meticulous 3D planning by the Pörner Group, the plant operators were already able to take virtual tour through the facility during the planning phase and also simulate the operation of all valves. Actuators are used to automate a considerable number of ball valves. In future, the fully automated process control system on the bioethanol plant will ensure that all processes will take place per mouse click. Now that several weeks of testing have been successfully completed, the Pischelsdorf bioethanol facility is set for commissioning in the spring of 2008 in order to satisfy the requirement in Austria for adding 4.4 % bioethanol to petrol. ■

Model of the completed facility.

InfoboxComponents/Pischelsdorf bioethanol plant:

Production plant Auxiliary and feed equipment

■ Feedstock and storage (silo)

■ Extinguisher water system

■ Mashing

■ Fermentation

■ Distillation and dehydration (alcohol drying)

■ Water extraction from vinasse and DDGS, drying and pelletising

■ Vinasse evaporation plant

■ Ethanol storage and filling

■ DDGS storage and filling

■ Catalyst storage, chemicals storage and CIP system

■ Washing and process water system

■ Cooling towers and cooling water system

■ Grain cleaning and milling

■ Air compressor and system

■ Energy centre with boiler and steam system

■ Transformers and electrical distribution system

■ Gas supply with gas reducer station

■ Control console and administration equipment

■ On-site road system, railway equipment and tracks

The KLINGER Ballostar KHE ball valve in use.

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Let the sun shine in

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In Sanlúcar la Mayor (Se-ville), Abengoa is planning to construct the world’s first commercial solar thermal power plant. The technology uses a central tower and a field of heliostats.

Saidi, Spain

If anything is in sufficient supply in Andalusia, it must be the sun. In response to this immense potential, Abengoa Solar has for years been working on harnessing the sun’s energy to generate electricity, and in the coming years plans to build and

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operate a sophisticated facility in Sanlúcar la Mayor in the province of Seville. With 20 years in research and development in sun-energy projects, Abengoa Solar is a specialist in the design, promotion, construction and operation of plants that generate electric power by harnessing the sun as a primary source of energy. Technological support for the project has been provided at the highest level by a European consortium of companies and insti tutions, specialists in the field of concentrating sun

technologies, CIEMAT, the University of Seville through its Department of Energy and Thermodynamics and the German Institute of Aerospace Technology have all contributed experience that was acquired during development of this technology on the Solar Platform of Almeria. The PS10 solar power tower, the first of a set of power generation plants at the future ‘Plata-forma Solar de Sanlúcar la Mayor’, was successfully commissioned a few months ago. The PS10 solar thermal power plant of 11 MW rated capacity has been planned and managed by Sanlúcar Sun. Engineering development has been the responsibility of Solúcar Energy, with Abener Energy as the builder. All these companies are 100 %-owned by Abengoa. With the PS10 plant, they will be producing kWh 23,000,000 electricity per year -

enough energy to supply a town of 10,000 people - which will be fed to the national electricity grid. PS10 is a concentrating solar power (CSP) plant and operates on the principle of direct generation of saturated steam at re la t ively low temperature and pressure (250 °C and 40 bar). It comprises a wide spectrum of heliostats (mobile mirrors that reflect and concentrate the sun’s radiation on the receiver at the top of a tower). 264 mirrors of 120 m² reflective surface concentrate energy to a cavity receiver mounted on a 115 metre tower. The high energy at this point of concentrated sunlight is used to heat water pipes that provide 200 m² of water-cooled energy exchange surface area. The thermal energy produces steam that drives a turbine to generate electri-city. The PS10 project is the world’s first electricity producing tower that is both stable and commercial, and thus makes a major contribution of the development of this technology. Collaborating on the project with Abener Energy, Madrid-based SAIDI, part of the KLINGER Group of independent Companies, provides the valves and seals (ball valves, cast gate, globe and check valves of different rat-ings, connections and dimensions, forged valves, etc.) SAIDI will also be a supplier to the projected PS20 plant. This will be the second plant in the Solúcar Solar platform and will come on line after the PS10 with an annual gross output estimated at 50.6 Gwh, compared with PS10’s 23 Gwh. The PS20 tower will be 156 metres in height compared with 115 metres for the PS10. It, too, will produce electricity through photovoltaic panels and a solar thermal power plant using concentrating technology. ■

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Saidi, Spain

KLINGER DANMARK valves for new district heating tunnelKLINGER Danmark A/S, Denmark

To ensure greater efficiency, Copenhagen Energy has built a new 4 km long tunnel that runs at a depth of 25 – 40 metres below ground from the power plant Amagerværket to the dis-trict heating supply lines in Copenhagen.,

The tunnel will accommodate district heating water lines up to DN 700, steam lines up to DN 500, and a DN 400 condensate line. Copenhagen Energy has placed an order with KLINGER DANMARK for approximately 300 valves, which will be mounted in 3 shafts. For district heating water and condensate lines, KLINGER DANMARK will supply the KLINGER Ballostar KHSVI DN 200 - 700 with electrical actuators, the KLINGER Monoball KHS-H/KHFS-H DN 15 – 300 for manual shut-off, and the DN 700 KROMBACH RK510 swing check valve with hydraulic dampers. For the steam lines, KLINGER DANMARK will supply the DN 500 KROMBACH TRI-EX triple eccentric but-terfly valve with electrical actuators. ■

A: Condensate lineB: Steam lineC: District heating water

Photos and illustrations by Henrik Pyndt Sørensen

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BioLatina halves production costs ofenvironmentally sustainable equipmentRich. KLINGER Ind e Com Ltda, Brazil

A biodiesel production specialist cuts costs by using compressed fibre gaskets.’s first commercial solar thermal power plant. The technology uses a central tower and a field of heliostats. The production of biofuel is increasingly important in Brazil, reflecting the potential of the country’s energy sector. Biofuel - a key resource when it comes to reducing the environmental impact of industrial progress - is used as a substitute to fossil fuels in heavy goods haulage.One company manufacturing equipment for the production of biodiesel in Brazil is BioLatina Máquinas e Equipamentos Industriais, a joint venture between Brazilian group Ecogeo, which provides consulting services for the assembly and operation of systems and equip-ment in the environmental segment, and Swiss company Mecan Ecosystems AG, which develops technology for biodiesel production. BioLatina was founded in 2006 and produces the BDA-600 modular unit used to obtain biodiesel from vegetable oils and animal fat, along with other waste that’s in abundant supply in Brazil. BDA-600 units have an operating capacity of 5 million litres per year, and are generally

Better suited gaskets Previously, BioLatina equip-ment relied on metallic gaskets at the flange connections. After consulting specialists from KLINGER, the company realised this material was being used inappropriately since these stations do not operate under high temperature or pressure conditions. BioLatina decided to substitute the metallic gaskets with a more efficient solution - compressed fibre gaskets from the KLINGERSIL® range. Besides being expensive, the metallic gaskets were difficult to store. “Our aim was to source gaskets from an internationally respected company with a cost-benefit ratio that met our needs and

with the same efficiency as metallic gaskets,” says Vinicius Ambrogi, a project engineer with the company. “KLINGER came up with an effective substitute, with no adverse technical issues.” KLINGER recommended C-4430 jointing, an asbestos-free material from the KLINGERSIL® range well suited to the BDA-600 units. Made from synthetic and glass fibres with NBR rubber, the compressed fibre gaskets are supplied pre-cut and ready to use in order to facilitate assembly and maximise the use of the material. According to Ambrogi, by changing metallic gaskets from KLINGER compressed fibre, the company has slashed material costs by half. ■

Vinicius Ambrogi, BioLatina Project Engineer:C-4430 compressed fibre gaskets from the KLINGERSIL® range meet the needs of BDA-600 units.

used for small-scale industrial produc-tion by cold-storage plants, cooperatives and haulage con-tractors, for example. Requiring a single operator only, the units are highly automated and can function for over 8,000 hours per year. ■

BioLatina: Swiss technology for the construction of modular units for biodiesel production.

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From wood to fuelKLINGER SCHÖNEBERG GmbH, Germany

KLINGER SCHÖNEBERG and KEMPCHEN contribute to brand new technologies.first

Biomass to energy of the second generation Biomass is an infinite resource. Throughout history, it has been used as food or fodder, or as a fuel to generate heat. High-energy biomass containing carbon is made from CO2, water and small amounts of plant nutrients, with sunlight acting as the catalyst.

Technology Far removed from conventional processes to create fuel out of vegetable oil, at the heart of the unique technology from Choren Industries GmbH of Ger-

many is the patented Carbo-V® process. This totally new, multi-stage gasification process produces environmentally friendly fuel from biomass. Solid biomass such as wood can be converted into a combustion or synthesis gas. This gas mainly contains CO and H2 and is in turn converted into liquid hydrocarbons by a catalytic process known as Fischer-Tropsch synthesis. For both plants, Choren is putting its trust in our quality products: namely, KEMPCHEN sealing technology and KLINGER SCHÖNEBERG high-perfor-mance ball valves. ■

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A new-look Internet presenceKLINGER Fluid Control GmbH, Austria

KLINGER Fluid Control’s new website has been online since 15 November 2007 with an up-to-date design that complies with KLINGER’s corporate identity guidelines and reflects the high status that’s granted topicality, professionalism and quality.But it is not only the exterior image that has undergone a radical makeover. Revised site navigation makes it easier to browse through the website, and the search function and site map make it quicker and easier to track down specific information. All contents have also been brought up to date, so there is now more

information than ever before. In addition to a detailed product overview, visitors also get interesting information on the company’s philosophy and history, as well as the dif-ferent departments. And for engineering offices and plant constructors, there are dimensional drawings of the stand-ard models in dfx format, ready for downloading. The website pages featuring application examples offer our customers and trading partners an insight into the wide range of uses for our industrial valves and at the same time emphasise the strength of our products: absolute dependability under

the most demanding conditions.To restrict public access to sensitive information and documents, we have once again created a members area that can only be accessed by KLINGER trade partners after entering their user name and password. ■

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Exclusive KLINGER distributor boosts turnover GROUPE EYNARD ROBIN, France

During this period, Eynard Robin continued to expand by acquiring or opening production facilities in France, a country with a strong industrial base. Among the new locations are Ey-nard Robin, Provence; Eynard Robin, Normandie; Eynard Robin, Fessenheim and Kempchen, France. In December 2005, Eynard Robin moved into a brand new, state-of-the-art head office in Saint-Fons in the south-ern suburbs of Lyon, and in June 2006 acquired Autoclavite, located in South-ern Paris. Autoclavite is a specialist in insulating components, flange protection devices and expansion joints, and also has a facility for rubber extrusions and mouldings - for Eynard Robin, all complementary activities. A particular speciality is the production of sealing components for chlorine cells. Eynard Robin is continuing to develop business in all designated French-speaking African countries. In particular, the group has created facilities for distribution and gasket fabrication in Morocco and the Ivory Coast. ■

Since becoming the exclusive KLINGER distributor for France and the French-speaking African countries four years ago, con-solidated turnover at Group Eynard Robin has risen from EUR 15 million to EUR 27 million.

Technical seminar for energy tech and industry customersKLINGER w Polsce Sp. z o.o., Poland

At the beginning of October, just under 60 invited guests from the district heat-ing, energy technology, chemicals, tire manufacture and paper and cellulose production sectors were given a com-prehensive overview of the KLINGER product range during a 2-day exchange of seal and valve information at Jedlnia, 100 kilometres to the south of Warsaw.

The full spectrum of seals from the KEMPCHEN company and the KLINGER range of fluid level indicator products were also introduced to customers, while Michael Heintschel (KLINGER Dichtungstechnik GmbH & CoKG, Austria) and Wolfgang Steinwender (KLINGER Fluid Control GmbH, Austria) took the opportunity to carry out intensive product training. ■

Eynard Robin Provence

Eynard Robin Head Office

Photos by Laurent Ferrari/Juan Carmona.

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Sharing information and experienceKLINGER Fluid Control GmbH, Austria

Tw o 2 - d a y a p p l i c a t i o n meetings were staged at the Gumpoldskirchen facility during October 2007 for trading partners from Western, Central and Eastern Europe. The main reason for the meetings? An exchange of information and experience between sales organisations and manufactu-rers when using KLINGER valves in the most varied industrial sectors.

In all, 30 partners from 20 countries took the opportunity to detail specialised applications for KLINGER ball and piston valves. Once again, it was clear that partners and end-customers are especially appreciative of the high quality, dependability and long service life of KLINGER products. The exceptional technical properties of KLINGER’s industrial flow control devices mean they can be used in areas where the performance of competitors’ products comes no way near the life-span and dependability of KLINGER valves.

Equally, these meetings were a chance for manufacturer KLINGER Fluid Control to receive important customer feedback about the product range and also discuss future trends in the industrial flow control segment with representatives from the market. Helmut Loidl, Development Manager at KLINGER Fluid Control,

released details on the current status of new development. For the first time, the new full bore size DN1000 Ballostar KHI ball valve in both flange and welded versions was presented to the public. Our exper ts recorded a l l related information such as product design versions, features, installed location, operating medium and conditions on KLINGER’s special application forms before passing them to KLINGER Fluid Control for archiving. Following the meetings, they will be available as a collection on a single PDF document - an effective tool not only for marketing and sales, but also for reference purposes. We are looking forward to the next application meetings! They give a fascinating insight into the typical differences - and also similarities - between the different national sales markets, with the high level of attendance confirming the importance of shared experience. ■Applications of Ballostar KHA ball valves in the most varied industrial sectors, i.e. in

the fire extinguisher system of a Swiss tank farm, or in a Spanish cement factory for a mixture of cement and water.

Our partners from Austria, Bel-gium, Denmark, France, Greece, Italy, the Netherlands, Norway, Portugal, Spain and Switzer-land.

KLINGER trading partners from Central and Eastern Europe on a tour through the assembly shop.

KLINGER w Polsce Sp. z o.o., Poland

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KLINGER ADMINISTRATION AGIndustrie Nord, Seonerstrasse 2875704 Egliswil/SwitzerlandT +41(0)62 769 30 11 F +41(0)62 769 30 13